Flexible dies are gaining increased use in a broad range of converting tasks, offering a cost-effective alternative without compromising quality. Wilson Manufacturing provides a full family of precision-made flexible dies that are manufactured with hardened spring steel for durability, and use chemical etching and computer-to-plate technology to ensure premium quality. For improved, longer-lasting cutting performance its flexible dies are also machine-sharpened. Applicable for nearly all labeling materials and applications, Wilson’s flexible dies can be manufactured to cut pressure-sensitive, metal-to-metal, two-level, crease, perf, or slit-over-perf applications.

Wade Fouts, VP of sales for Wilson Manufacturing, says that one of the keys to successful application of flexible dies is to start with products from a well-established supplier, and then apply proper maintenance and handling techniques. This includes care of the magnetic cylinders. “Converting with flexible dies requires proper magnetic cylinder maintenance, including cleaning, lubrication, and storage,” he states. “Flexible dies cannot perform to their fullest potential with a magnetic cylinder that is not produced to stringent quality standards. Always store dies and cylinders in their original protective packaging, keep the magnetic surface clean, and keep the bearer surfaces lubricated when running. Following these tips will result in maximum effectiveness and profitability of flexible dies.”

Kocher+Beck’s Gluex line of high-precision flexible dies are specially coated to prevent adhesive and ink adhering to the cutting edge, as well as adhesive bridging between the label and grid matrix. Gluex Plus offers a high non-stick effect for standard applications, with a special coating that prevents the migration of adhesive and ink. Gluex Ultra incorporates a new type of special coating (food-safe/FDA-compliant) that is designed for optimum cutting and label quality.

David Morris, senior executive VP for Kocher+Beck, notes the increasing focus on thinner liners and the need for label application lines to run faster and with less downtime. “Label manufacturers no longer have to just focus on the quality of the cut, they must also focus on achieving the minimum die strike on the liner,” he says. “Clean conversion of the face material is key, but so is the die strike. A high-quality, tight-tolerance flexible die can help the label manufacturer achieve both things with ease.” Morris also emphasizes proper maintenance of flexible dies and cylinders and says the Kocher+Beck can provide on-site training and audits.

At ABOX Packaging, located in Kaufman, Texas, speed, efficiency, and quality are traits the company's growing customer base has come to expect. The 37-year-old packaging company, located 27 miles southeast of Dallas, is a custom manufacturer of high-end folding cartons, serving a variety of different market segments including medical, food packaging, and office supply products.

ABOX Packaging is led by industry-veteran Keith Thompson, who serves as the company's president. Thompson purchased ABOX Packaging nine years ago from the company's original owners.

"We have gone from 50 employees to 125 employees," Thompson proudly says. "And we are at 4 1/2 times the sales revenue from when I purchased the company."

Thompson attributes the company's success to his employees, who he refers to as "incredible". He also gives credit to the company's strong base of more than 200 customers. "They are very loyal," he contends. "We work hard to retain our customers."

Speed rules

If ABOX Packaging has a niche, it is speed, Thompson reports. "We can turn around a job in two or three days if needed," he says. "It's all about speed today. Anyone can buy a press that will print great, or a diecutter that will diecut. It's how quickly you can make it happen for the customer."

To address this need for speed, ABOX Packaging installed a Heidelberg Dymatrix 106 CSB (integrated cutting, stripping, and blanking) diecutter in late 2009. Thompson maintains that the addition of the Dymatrix machine has increased diecutting productivity by about 25 percent.

Thompson notes that the Dymatrix diecutter runs faster than the company's previous machines, which required offline blanking. ABOX Packaging can now diecut, strip, blank, and send jobs directly to the gluer, eliminating the need to perform manual scrapping or offline blanking.

"When I started looking at diecutters, I looked at three different brands," Thompson recalls. "And I was very impressed with the Heidelberg machine. Three years later we are incredibly happy with it. It has done exactly what they said it would do."